Quality Management System

Guidelines
Version 1.0 15 July 2014

Title:

NB QMS Guidelines

Version:

15 July 2014

Filename:

QMS Guidelines_V1.0_7.2014 ppt

Document owner: Mark Woodworth Manager Regional Quality Control, Asia

Distribution:

NB Factory Quality Teams/LOs in Asia

Contents
1.

Introduction
1.1. Background
1.2. Purpose
1.3. QMS Organization Structure
1.4. Recruitment and Training QMS personnel

2.

QMS Guidelines
2.1 Incoming Materials Warehouse and Inspection
2.2 Implementation On the Line
2.3 Finish Goods Warehouse

1. Introduction
1.1 Background
The New Balance Quality Management System (QMS) detailed in these
Guidelines are recommended actions for monitoring and controlling quality from Incoming Materials
through the production process to the Finished Goods Warehouse and Shipping Inspections.
These Guidelines will be focused on achieving New Balance quality policies
and objectives to ensure we are meeting our customers wants and
needs and will be expressed as the organizational structure, policies,
procedures, processes and resources needed to implement effective
quality management.

1.2 Purpose
The purpose of the NB QMS Guidelines is to provide our T1 factories a clear, but flexible set of
requirements to control footwear product quality end-to-end and provide the basis for periodic
audit by NB, as well as to create mutual trust and greater synergy with our factory partners.

1. Introduction
1.3 QMS Organization Structure
NB T1 factories must prepare a QMS organization chart in the format shown below.

QMS Manager

QMS Procedure

QMS Supervisor

RQC

EOLQC

QMS Supervisor

RQC

EOLQC

QMS Supervisor

RQC

EOLQC

1. Introduction
1.4 Recruitment & Training QMS Personnel
For the recruiting and training of QMS Personnel such as EOL Inspectors,
Roving QC Inspectors & SI Inspectors from both inside and outside the factory
(see attachment).

2. QMS Guidelines Scope

2.1 Incoming Materials W/H & Inspection

2.2 Implementation on the Line

(Quality Control in Production)
2.3 Finished Goods Warehouse

2.1
Incoming Materials
Warehouse & Inspection

Incoming Material Warehouse Lay out

Incoming
Materials

Reject
Area

Release Area

Preparation
Area

Inspection Areas

Incoming
Materials

Release Area

Excess
Material

A = Leather Inspection
B = Synthetic Inspection
C = Accessories Inspection
As shown in the drawing, background color of area location ID signs should be same color as borders.
The lettering color on the area ID signs should be in contrast to the background color.
9

Incoming material Warehouse Color Coding

Material Storage Areas
Five colors are used to mark and identify location areas of material
storage according to material inspection status
Blue GreenYellow Grey Red -

Incoming Inspection Area

Released Area
Preparation Area
Excess Materials Area
Rejected Area ( use Brown color for floor lines)

Color borders can be:

Painted: for permanent use

Taped: for temporary use

Width of borders = 60mm (recommended)

Flow Process Incoming Material

Unload material from
truck or container

Pass

Fill out Tracking

Sticker with Failed
Inspection result

Y
Place material in
Inspection area

Attach Tracking
Sticker and fill out
material information

Attach Red
Rejected sticker and
move to rejected area

Physical test

Pass

Claim to T2 supplier

Y
Visual inspection

Fill out tracking

Sticker with passed
Inspection result

Attach Green
Released sticker and
move to release area

Incoming Material Tracking Stickers

Material Name
Supplier Name
This material tracking sticker must be placed on all
incoming materials (1 per unit) for all incoming
materials.

PO. No.

Stickers have White background with Black lettering.

Date Received

Roll No/Lot/Batch

Expire Date
Quantity
Production Month
to be checked prior release

PASS FAIL

FIFO

Lab Test Result

Visual result (Material)
Dimensional Result
Defect & grading check
Packing
Checker/QC Signature
QA/APP/03/00/00-APPENDIX-3

Standard size is 100mm by 100mm.

12

FIFO (First it First out)

A FIFO sticker must be applied to all incoming materials.
For hardener, primer and adhesive chemicals:
the FIFO tracking month is the chemicals production date.
For all other raw materials the FIFO month is the date the material arrives in the Incoming W/H
The background colors for the FIFO stickers are different month by month so 12 colors are
used representing each month of the year. The month number is also printed on the sticker
An underline in added to number 6 and 9 to avoid confusion.

Diameter 30 mm

10 11

6
12
13

13

Size & Location of Indication boards

The size of the area identification (ID) signs should be: A2
Placement of material location signs.

Area Location ID signs: Either hanging or place on walls indicating , Incoming

Inspection area, Released area, Reject area, Preparation area or Excess Material
area.

Storage row location signs: are placed at the top of the entrance to each row.
Storage Shelf Bins/Sections:
Each storage Row should be numbered 1,2,3,4, etc.
Each shelve bins/section location should be identified by a letter e.g., A, B, C, D,
At the entrance to each Row there should be a material location board
which shows the row and bin/section location number and letter;
For example 2F = Row number 2, Bin/Section F.
With this system materials can be easily located.

Material location boards which show the Row and Bin/Section

location number and letter

Area Location ID Signs

Examples of area ID signs

Rejected area ( A2 size )

Released area (A2 size)

Released area ( A2 size )

PT. SINAR TIMUR INDUSTRINDO

REJECTED

Example of Rejected sticker

(order with individual factory name)

PT. SINAR TIMUR INDUSTRINDO

RELEASED
Yes:
The sticker size is
95mm x 35mm

Example of Released sticker

Released Material Area

Materials must be transferred from the Inspection holding area to the Released storage area after passing
inspection.
Shelves for Released material should be in a separate location for storage and marked properly.
Material status boards should be posted to the front end of the shelf with material information & location.
Release and FIFO stickers on each item should face the aisle.

Incoming Material Area

The Color Blue Area Location ID Sign indicates
this area is for Incoming Materials and Inspection

April 2014

Example of Temporary Released/ Rejected Holding Areas

In the Incoming Inspection Warehouse, Temporary

Holding Areas for Released/ Rejected material
must be clearly identified with correct color
signs (Green for Released and Red for
Rejected).

Note that the

color Brown is
used for painted
lines on the floor

Material Preparation Area

The Material Preparation area is a separate area, where Released materials are prepared for issuance
to production. The PREPARATION area is identified with a Yellow color area ID sign.

21

Incoming Material Warehouse

Rejected Material Areas
Rejected materials are those which do not pass either the visual inspection or the physical inspection.
Rejected materials should be claimed back to suppliers in accordance with the respective country specific
policy.
The Rejected Material Area should be secured with a lock to avoid mixing with all other materials and an A4
size information sheet with a color photo, name and contact number of the person who controls the key must
be posted near the lock.
NOTE: The key must be kept by a QMS team member

22

Table to be posted on the wall

Matrix for Visual Inspection of Incoming Material
General Level Inspection
Normal Inspection

Level Of Inspection
Inspection Method
AQC Score

Sample Number

Accepted / Released
n

Incoming Lot

2,5

AC

AC

AC

Re

Re

Re

0
1
0
1

0
1
0

0
1
0

0
1
0
1
0
1
0
1

1
0
1
0
1
0
2
1
2

1
0
1
0
2
1
2
2
3

1
2
1
2

2
2
3
4

4
5
6

3
3
3
4

6
6

0- 8

.9 - 15

16 - 25

26 - 50

51 - 90

13

91 - 150

20

151 - 200

32

2001 - 500

50

5001 - 1200

80

1201 - 3000

126

3001 - 10.000

200

4
6

11

15

10.001 - 36.000

315

7
8

14
15

21
22

36.001 - 70.000

600

70.001 - 120.000

1000

12.001 - 170.000

1250

170.001 - 250.000
( over 250.000 include material )

2000

7
9

7
8
10
11

10

14

10

21

11

22

21
22

14
15

21
22

21
22

21

21

22

22
21
22

21
22

21
22

21
22

NOTE :
1 . In program of materials inspection of parts of to be check visually as according to " visual Form Inspection of Incamoing material " : Hardness, Thickness ,Color
Appearance.Level inspection from material arrival differe can be altered by pursuant to former inspection wxperience.Classification assessment from supplier or
over all of material type will give an indocation to handle the inspection random by more flexible .
2. Material which Rejected have to re-inspect by increase up 1 level,if level 1 have been used ,do by 100% inspection.if material 2 time do by 100% inspection.
3. We have 3 level defect ( AQL 1 for Tight Inspection / AQL 2,5 for Normal Inspection / AQL 4 for minor Inspection.

Incoming Materials Inspection

Accessories are inspected:
a. By Piece
Shoe laces, transfer paper, size labels, TR Counters, D-rings, heel plugs,
Booklets, Hang Tags, Eyelets
b. In Rolls/meters
Thread, Velcro, Webbing, Elastic Gore

c. In Sheets
Outer Carton boxes, Inner boxes

Incoming Material QC Workstations

Each QC should have clear workstation
And clear visual colored area to place:
Green : released material
Blue : waiting inspection
Red : rejected

Visual Inspection of Leather

For checking:
- Material appearance: Refer to Confirmed Shoes (PCS), Spec sheet/OIB
- Color: Refer to Swatch and or PCS
- Thickness: Use gauges
- Hardness: Use hardness gauge

- Dimensions: Use ruler, tape and/or caliper

Note: If material FAILs visual inspection it does not need to be sent to the lab for physical testing.

26

Examples of tools Incoming Inspection QCs must have on hand for proper inspection of Leather:

1. Measuring devices

2. Material swatch
books

3. PCS in place and used during inspection

27

Incoming Leather Materials

Each factory should prepare a Leather Defect catalogue to be used during Inspection
Examples of Items to Include in DEFECT CATALOGUE
SCRATCHES

BACKING HAIRY

LOOSE GRAIN

GROWTH MARKS

BRAND MARKS

TICK MARKS

4.4 eIncoming Materials Lab Testing

Method and Tools

Physical/Lab - Testing
- All Incoming materials must pass physical lab tests before being Release.
- Test frequency for each type and batch of material is established by the NB Lab Manager.
- Physical testing for production materials must be conducted according to NB standards.
- Specimens should be taken only by authorized QMS QC personnel.

29

Table to be posted on the wall

STANDARD TABLE OF RANDOM SAMPLING PHYSICAL TEST
NO

MATERIAL NAME
LEATHER

OUTSOLE/MIDSOLE
INLAYSOLE
2

TEXTILE,PVC, SYNTHETIC

RECEIVED
QUANTITY

RANDOM SAMPLING QUANTITY

FOR PHYSICAL TEST

- 20.000 sf

1 Piece

20.001

- 40.000 sf

2 Piece

40.001

- 60.000 sf

3 Piece

60.001

- .

4 Piece

- 5.000 prs

1 Pairs

5.001

- 10.000 prs

2 Pairs

10.001

- 20.000 prs

3 Pairs

20.001

- .

4 Pairs

- 50 Rolls

1 Roll / Type

51

- 100 Rolls

2 Roll / type

101

- 150 Rolls

3 Roll / Type

151

- .

4 roll ? Type

ACCESSORIES
Material type " A "
1 Specimen for once physical Test
0

- 25 Cartons

1 Specimen for once physical Test

26

- 50 cartons

1 Specimen for once physical Test

51

- ..

Material Type " B "

4

- 100 Rolls

1 Specimen for once physical Test

101

- 200 Rolls

1 Specimen for once physical Test

201

- .

1 Specimen for once physical Test

Material Type " C "

- 10.000 pcs

1 Specimen for once physical Test

1.0001

- 20.000 pcs

1 Specimen for once physical Test

20.001

- ....

1 Specimen for once physical Test

Remark : Material Type "A" = Carton Box and Inner Boxes

Material Type "B" = thread, webbing tape, Velcro, Plastic band
Material Type "C" + TR Counter, Torsion Bar,TPR Logo,Button,eyelet,Shoe
Label,Sticker,Booklet,Transfer Label

Lace,Tongue,Label,Hang Tag,Size

REMARK

2.2
Implementation On the Line
(Quality Control in Production)

Implementation on the Line

Product supervisors are responsible for controlling process and product
quality during Implementation on the Line. However, quality control is enhance
by adding QC Inspectors, Roving Inspectors (RQC) and End-of-Line QC
inspectors (EOL QC).

Generally:
1 QC Inspector at the end of each upper stitching line;
1 or 2 EOL QC at the end of each production line; and,
1 RQC to cover no more than two production lines

32

Roving & EOL QC Identification

Colored hats must be worn by both the QMS Roving (RQC) and the EOL QC.
Other QC personnel my have colored shirts or hats to identify them as well:
A. RQC or Roving = Orange color hats with Black letters
B. EOL QC = Red color hats with Yellow letters
C. Incoming W/H, Rubber Room and Stitching QCs also
= Red color hats with Yellow letters

End-of-Line QC
(EOL QC)

Responsibilities for EOL QC

EOL QCs are placed at the end of each production line to
conduct visual inspection of 100% of the product that flows
from that line.

EOL QC

EOL QCs must have sufficient work space and good lighting to conduct proper inspection of the product.

All required tools and materials below should be available:

a. QC Red arrow stickers
b. Daily Quality Report
c. Pen to record defects on the Daily Quality Report
d. Clip board to hold Daily Quality Report
e. 6 inch steel ruler
f. Inspection tooling gauge to measure stitch length
g. B- Grade stamp
h. PCS update per 3 months
36

Two (2) Defect Carts on wheels should be available for the EOL QC to place defective shoes
The Defect Carts should have 3-4 shelves labelled Dirty - Assembly - Stitching & Cutting.
When 1 Cart is full the EOL QC turns the shoes over to the production line supervisor and then takes
the 2nd Cart back to the work station. The Line supervisor takes the Defect Cart to each applicable location
and returns the shoes to the appropriate operators to be repaired. The operators repair the defects
(when possible) and place the shoes back on the line.

Good lighting
The EOL QC also needs proper lighting to be able to see and identify defects clearly

An EOL QCs Workstation

Defects Cart
37

EOL QC Work station

The EOL QC Work station for EOL QC must be clearly Identified with a large sign Above the work
station (Yellow background with Red lettering).

The EOL QC must consistently identify defect locations on product using defect arrow stickers and
must record each defect on a Daily Quality Report .

38

5.2 Tollgate Quality Control EOL

5.2 Tollgate Quality
Controlat(TQC)
after assembly and stitching
B-Grades
EOL QC
areas
Certified EOL QCs are empowered to B-grade product when necessary. For this
purpose a lockable Red colored box must be placed at each EOL QC work station to
temporarily secure B- Grade shoes until the end of the day:

NOTE:
EOL QCs must be empowered to make decision to B-Grade shoes and stop the line
39

5.2 Tollgate Quality Control EOL

Repairs at EOL QC
No repair is allowed by EOL QCs.

EOL QC is not allowed to use scissors to trim or rubber to clean shoes

40

5.2 Tollgate Quality Control EOL

Metal Detection at EOL QC

Metal detectors must be used to detect any contamination of metal such as,
broken needle fragments or metal filings in materials or stuffing paper.

All shoes are passes through the Metal Detector after the EOL QC check.
a. If the MD alarm sounds or flashes as the shoes pass through the shoes are isolated
b. The RQC and Line Supervisor will use handheld MD to determine if metal is detected in L or R shoe
c. If metal detected, shoe is cut to locate metal object and report

MDs are Calibrated by RQC Twice Daily

ALERT

STEP 1

CENTER

LEFT

MDs alarm should sound

and the machine
should stop.

RIGHT

Ferrous ball test

stick diameter
1.5 mm

Put Ferrous test-tick in the center then left

and right side and pass through the conveyor belt

ALERT

STEP 2

CENTER
Put the Ferrous testtick on top of a 50
mm High box
in the center ans
pass through the
conveyor belt

MDs alarm should

sound and the
machine
should stop.

STEP 3

MIDDLE
Put Non Ferrous testtick in the center and
pass through the
conveyor belt

Non Ferrous
ball test-tick
diameter 2 mm

STITCHING QC

Stitching QC Check Points for Inspection of Stitched Uppers

1

Check top view of Uppers

(eyestay & eyelet alignment ,

Check Heel area

Check inside of uppers

(Logo, heel patch and back tab must be centered)

(lining stitched around toe , no

logos & toe centered)

thread ends or excess cement )

Check tongue

Check size labels

(Stitched in straight, collar lining even,

Centred and consistent

All folding must be flat)

Examples of common issues Stitching QCs look for

Loose thread ends

Logo wrinkles

Inconsistent alignment of
webbing

Misaligned notches and

Stains or cement on uppers

Inconsistent Stitching margin

Stitching open

Examples of common issues Stitching QCs look for

Vamp/toe shape off center

Upper wrinkles

Misalignment

Damage punched holes

Visible gauge marks

Misaligned or excess
Reinforcement

ROVING QC
(RQC)

Responsibilities for RQC

RQCs monitor and control process and product quality from
cut to box . An RQC should only be responsible for
maximum of two (2) production lines.

RQC
Checklist

RQCs Duties
Ensure that a correct SOP is clearly displayed (in color) at each operator work station

3
SOP Check Points:
1. Clearly explains the SOP for the specific process in production
2. SOP shows critical areas to check.
3. SOP has correct reference number
49

Roving QC (RQC)
Example RQC Checklist

RQCs must carry their work instruction and Daily Checklist with them on a clip board.
NOTE: RQCs are monitoring production lines to control quality consistency. They should be
well trained in production processes and NB quality standards and demonstrate good
self-confidence and decision making ability.
50

RQCs monitor machine settings and operating times, temperatures, pressure

and work closely with production supervisors to ensure any issues are

addressed and resolved quickly.

51

RQCs Check Cutting Boards

Cutting Boards need to be color coded on two opposite end corners to facilitate control
- Every 4 hours the cutting board should be turned 180 (showing a different color)

- Every 8 hours the cutting board should be flipped over to ensure optimal use of cutting surface

Painted colors on corners

Note : Cutting board should

be in good condition to ensure
smooth edge cutting

52

RQCs Check Cut Components

Control of Cut Components
Cut Components are generally placed in
plastic baskets to maintain control by size
and quantity and to keep them clean.
-Baskets should be clean and the
-Component size and quantity should
-be marked on the end of the basket

x
Note : Component Quality and
Quantities must be controlled
53

Examples of common issues RQCs look for at Cutting

Poor Perforation holes

Cutting dies not matching

pattern

Creases in layered materials

Hairy edges of cut components

Damaged components

RQCs Check Cutting Dies

Control Cutting dies
- Cutting dies must be flat

- Cutting dies must be sharp

- Cutting dies should not become rusty
- Cutting dies are placed in EVA material cut-out
- to prevent cutting knife edge damage

Note : Cutting dies should

not become rusty

55

Cutting Die

Pattern

100% flat glass

RQCs Cutting Die Check

Operator check if deform before operation

Check if surface flat

RQCs should check that pattern construction is correct

RQCs check that Zig-Zag stitching is correct

Width stitching 5 -6 mm
Left and Right
components height must
be flat

L Component

R Component
Component must be flat
Not overlap

Locked stitch 3 4 stitches

c
ab

Range right stitch and left

must the same (ab = bc)

size code

RQCs should monitor Daily Broken Needle Reports

The issue of needles to the operators is controlled by the Stitching Supervisor.
When an operator has a broken needle they must immediately call their
Supervisor and the RQC to report and locate all broken needle pieces.
After locating all broken pieces of the needle, they are taped onto a Daily Broken Needle
Report and the Date, Cell # and PO are recorded.
The supervisor may then issue a new needle to the operator.

Needles are
controlled by
Supervisor

All broken pieces must be found before

new needle can be issued to operator

59

RQCs Duties include checking Processes

RQC checks that Critical processes are being done correctly:

Strobel stitching to attach the Strobel board to the

upper.
Strobel stitching should be closed all the way around
and flat.

Back part molding

Times and Temperatures
must be checked

RQCs Duties include checking Processes

Lasting Process

Hand Buffing Process

Buffing the surface of leather to
create a strong bond

RQCs Duties include checking Processes

RQC checks that Critical processes are being done correctly:

Priming, Cementing Process

Primer and cementing
must be even.

Attaching Process
The function is to attach
the upper and bottom
unit following the parking
and buffing process

RQCs Duties include checking Processes

Pressing Process
The function is pressing the
upper and outsole together
to ensure a solid bond.

Insert & Components

All components for use in
production i.e. Inserts,
Strobel boards, heel counters
etc., must be clearly
separated and marked by size
for clear visual identification

Note : Toe stuffing paper should be inserted after EOL QC

1. Ensure the pressing pad

size is correct
2. General pressing
standard is 30 kg/ cm for
10 seconds.

Examples of common issues RQCs look for

Poor Alignment

Loose/open Strobel

Bonding

Off center heel

Wrinkled Midsole

Over cementing

* All the defects refer to NB Defects classification

Examples of common issues RQCs look for

Inconsistent Toe spring

Lining not caught by Strobel

stitching

Variation in
Heel Heights

RQCs Monitor Chemical Color Codes

Examples of required bowl covers with colored stickers to identify primer or cement and
solvent or water based as well as the shelf life times the chemical may be used i.e.,
11:00 12:00 or 15:00 16:00 for example.
Visual color coding for chemical Bowls and Brushes

Application Brushes are color coded and should follow the same color as the bowl cover i.e., a BLUE bowl
cover requires that the Operator also be using a BLUE colored brush. The change times should be clearly
posted at the workstation

66

RQCs Monitor cleanliness and serviceability of shoe Lasts

Lasts should be cleaned and stored properly by sixe after each use

Note : Lasts must be clean and not damaged or rusted

67

RQCs Monitor Serviceability of Production Confirmation Samples (PCS)

Confirmation Sample Handling:
RQCs should monitor the PCSs to ensure they are clean and serviceable

All PCS should have signed hangtag attached showing last date reviewed
All PCS should be kept in Zip-lock plastic bags to keep them clean

If a PCS needs to be replaced, a half pair is taken from production and must be signed by both
the factory QMS Manager & the NB QA

68

2.3 Finish Goods Warehouse

Visual Color Management
Location & Status Board
SI Room Status Board
Row Separation
Stack Heights
Process Flow
Layout (Example)

69

Visual Color Management

Visual color codes in the Finished Goods W/H are designed :
1. To connect production, F/G warehouse , SI areas and
shipping for end to end monitoring .
2. To establish a tracking system to easily locate POs and quickly identify the
status of each PO.
3. To eliminate search time in locating F/Gs in the warehouse.
4. To implement a user friendly organized environment without continual shifting of PO location

5. To standardize the F/G process flow for easy monitoring and control.

70

Location Status Board

F/G Warehouse PO location & status board color code identification
a. Color codes for PO status in F/G Warehouse:
F/G warehouse status boards with magnets is preferred:
Yellow = for POs not yet complete
Blue = for POs completed and awaiting inspection
Green = for POs which have been inspected and released (ready for shipment).
Red = for POs inspected and rejected
Black = PO cannot pass through outer carton MD because of metal shoe part.

71

SI Room Status Board

Shipping Inspection Room Status Board Color Codes
b. Color code for SI Room PO status board for daily inspections
Blue magnet = for POs awaiting SI
Green magnet = for PO SI complete and released
Red magnet = for Rejected POs

72

Shipping Inspection holding area color codes

c. Colors code for SI holding area borders
Colors for border lines or stand-up signs in holding area outside SI room:
Blue = POs awaiting inspection
Green = POs already inspected and released
Red = POs Rejected

73

Warehouse Row Border Lines

Color codes identification for Border Lines in the F/G W/H
Row border line colors (painted on the floor )

For Scan & Pack area = White Border Lines

For all other POs = Lines may be any color except RED, BLUE, or GREEN

Row number should be painted on floor at the front of each row

This factory is

using orange color

for Warehouse row
boarders

74

Color Code Identification Magnets

e. Colored magnets are preferred to attach to Row Placards to identify PO status
Yellow Magnet = PO not yet complete
Blue Magnet = PO complete and awaiting inspection .
Green Magnet = PO inspected and released, ready for shipment.
Red Magnet = PO rejected and awaiting re-inspection or other disposition.
Black Magnet = PO cannot pass through outer carton MD because of metal shoe part.

Use of Magnets makes it easy to update PO status throughout the process.

75

Recommended Warehouse Row Separation Distance

+ - 1 meter

76

Carton Stacking Heights

The purpose of limiting carton stack heights is to prevent crushing or
damaging cartons from stacks that are too high or too heavy.
The recommend stack heights are :
Ms/Ws ( size ) = 6 cartons high
Junior / Kids ( size ) = 7 cartons high
Note: Factories need to use best judgment for heavier/larger cartons (4 or 5 high)

6 cartons high

7 cartons high
77

END